U.S. patent number 10,202,816 [Application Number 15/669,312] was granted by the patent office on 2019-02-12 for apparatus and method of manufacture for retrofittable containment cellar.
The grantee listed for this patent is Mikel R. Stierwalt. Invention is credited to Mikel R. Stierwalt.
United States Patent |
10,202,816 |
Stierwalt |
February 12, 2019 |
Apparatus and method of manufacture for retrofittable containment
cellar
Abstract
A modular well containment cellar system having a bottom
portion, two co-planar half-panels joined to the bottom portion and
separated by a through-channel portion, and a one side wall joined
to a bottom portion and to the half-panels, forming a closed
container with an open top for mating to another cellar component
at the half-panels, wherein a well pipe may be received into the
through-channel. A plurality of drip diverters prevent
downward-moving liquid from running between the mated half-panels
and between the well pipe and the through-channel, to capture
dripped and running liquids from above the containment cellar
system.
Inventors: |
Stierwalt; Mikel R. (Shidler,
OK) |
Applicant: |
Name |
City |
State |
Country |
Type |
Stierwalt; Mikel R. |
Shidler |
OK |
US |
|
|
Family
ID: |
65229193 |
Appl.
No.: |
15/669,312 |
Filed: |
August 4, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B
33/03 (20130101); E21B 43/0122 (20130101) |
Current International
Class: |
E21B
33/03 (20060101) |
Field of
Search: |
;175/211 ;166/337 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Wikipedia; "File: Welhead-dueal completion.jpg", retrieved on Jun.
19, 2017 from
https://it.wikipedia.org/wiki/File:Wellhead-dual_completion.jpg- .
cited by applicant .
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Production"; retrieved on Jun. 19, 2017 from
http://www.upstreamepumping.com. cited by applicant .
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Jun. 19, 2017 from
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d=627B4C86DE72CCFE5B5CE4EOCADF4AAADCE9D566&thid=OIP.XphzHalzEVpknT-g3YcsVg-
EsDh&q=oil+well+head&simid=607996740311976370&selectedIndex=0&ajaxhist=0.
cited by applicant .
Adoil; Titan Containment; retrieved on Jun. 19, 2017 from
http://adoil.net/titan-containment/. cited by applicant .
Osha; "Cellar" definition; retrieved on Jun. 15, 2017 from
https://www.osha.gov/SLTC/etools/oilandgas/Illustrated_glossary/cellar.ht-
ml. cited by applicant .
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https://definedterm.com/a/definition/193893. cited by applicant
.
Cellar Tech; "Containment Cellars", retrieved on Jun. 15, 2017 from
http://cellartech.com/containment-well-cellars/. cited by applicant
.
Cellar Tech; "Containment Well Systems", retrieved on Jun. 15, 2017
from
http://cellartech.com/wp-content/uploads/2016/07/Cellar-Tech-Well-Cellar--
Presentation.pdf. cited by applicant .
Cellar Tech; Containment Well Cellar Installation; retrieved on
Jun. 15, 2017 from http://cellartech.com/well-cellar-Installation/.
cited by applicant .
Iadc Lexicon; "Cellar" definition; retrieved on Jun. 15, 2017 from
http://www.iadclexicon.org/cellar/. cited by applicant .
Croft Systems; The Difference Between a Wellhead & Christmas
Tree; retrieved on Jun. 15, 2017 from https://www.croftsystems.net.
cited by applicant .
OGPE; "Oil, gas well cellars / trenches access wellhead equipment";
May 31, 2011. cited by applicant.
|
Primary Examiner: Bagnell; David J
Assistant Examiner: Akaragwe; Yanick A
Attorney, Agent or Firm: Frantz; Robert H.
Claims
What is claimed is:
1. A modular well containment cellar system comprising: a bottom
portion having at least two edges; two co-planar half-panels,
joined to a first edge of the bottom portion and separated by a
through-channel portion between the half-panels; at least one side
wall joined to a second edge of the bottom portion and joined to
the half-panels, thereby forming a closed container with an open
top for mating to another modular well containment cellar component
at the half-panels for receiving a well pipe into the
through-channel; and a plurality of drip diverters which divert
downward-moving liquid from running between a pair or more of mated
half-panels and between the well pipe and the through-channel,
thereby avoiding reliance upon sealants or gaskets between mated
half-panels; thereby, the well containment cellar being adapted for
installation to a well head in a pair or more of containment
components such that dripping and running liquids from above the
containment cellar system are captured the well pipe is encased
between a pair or more of the mated through-channels, and the well
pipe is isolated from exposure to the captured liquids.
2. The system as set forth in claim 1 wherein the second edge of
the bottom portion is an arc-like edge, and wherein the side wall
comprises a curved wall.
3. The system as set forth in claim 1 wherein the second edge of
the bottom portion comprises two or more straight edges, and
wherein the side wall comprises two or more flat panels.
4. The system as set forth in claim 3 wherein the second edge of
the bottom portion comprises three straight edges, and wherein the
side wall comprises three panels.
5. The system as set forth in claim 1 wherein the plurality of drip
diverters comprise at least one ridge cap for installation across a
pair of top edges of mated half-panels.
6. The system as set forth in claim 1 wherein the plurality of drip
diverters comprise at least one drip cone for affixing around the
well pipe above the open top of the system, having a sufficient
lower diameter to divert running and dripping liquids into the open
top and away from top edges of the mating half-panels.
7. The system as set forth in claim 1 wherein one or more of the
half-panels, side, wall and bottom portion are joined by frame
members.
8. The system as set forth in claim 7 wherein one or more the
half-panels, the side wall, and the bottom portion comprises sheet
material affixed to the frame members.
9. A method of manufacture of a modular well containment cellar
comprising: forming each of a plurality of containment components
by: providing a bottom portion having at least two edges; providing
two co-planar half-panels, joined to a first edge of the bottom
portion and separated by a through-channel portion between the
half-panels; and providing at least one side wall joined to a
second edge of the bottom portion and joined to the half-panels,
thereby forming a closed container with an open top for mating to
another containment component at the half-panels for receiving a
well pipe into the through-channel; and forming a plurality of drip
diverters which, when installed to a well head in a pair or more of
containment components, divert downward-moving liquid from running
between a pair or more of mated half-panels and between the well
pipe and the through-channel, thereby avoiding reliance upon
sealants or gaskets between mated half-panels; thereby, adapting
the well containment cellar for installation to a well head in a
pair or more of containment components such that dripping and
running liquids from above the containment cellar system are
captured the well pipe is encased between a pair or more of the
mated through-channels, and the well pipe is isolated from exposure
to the captured liquids.
10. The method as set forth in claim 9 wherein the second edge of
the bottom portion is an arc-like edge, and wherein the side wall
comprises a curved wall.
11. The method as set forth in claim 9 wherein the second edge of
the bottom portion comprises two or more straight edges, and
wherein the side wall comprises two or more flat panels.
12. The method as set forth in claim 11 wherein the second edge of
the bottom portion comprises three straight edges, and wherein the
side wall comprises three panels.
13. The method as set forth in claim 9 wherein the plurality of
drip diverters comprise at least one ridge cap for installation
across a pair of top edges of mated half-panels.
14. The method as set forth in claim 9 wherein the plurality of
drip diverters comprise at least one drip cone for affixing around
the well pipe above the open top of the system, having a sufficient
lower diameter to divert running and dripping liquids into the open
top and away from top edges of the mating half-panels.
15. The method as set forth in claim 9 wherein one or more of the
half-panels, side, wall and bottom portion are joined by frame
members.
16. The method as set forth in claim 15 wherein one or more the
half-panels, the side wall, and the bottom portion comprises sheet
material affixed to the frame members.
17. The method as set forth in claim 9 wherein the half-panels,
side, wall and bottom portion comprise one or more materials
selected from the group consisting of fiberglass, plastic,
steel-reinforced concrete, stainless steel, and aluminum.
Description
FIELD OF THE INVENTION
The invention generally relates technologies to contain leakage and
small-scale spills from well heads and "Christmas tree"
assemblies.
BACKGROUND OF INVENTION
Well heads for oil and gas wells are often topped by a plurality of
system components, such as blow out preventers, gauges, and valves
atop the production casing. The combination of components mounted
atop the well head is often referred to as a "Christmas tree", or
"tree" for short. The junction between the well head and the tree
may be just above ground level, at ground level, or slightly below
ground level.
Many of these connections and components may leak some oil, salt
water, or often a combination of both. This leakage may drip, run
or fall onto the ground surrounding the well head, causing
environmental damage, danger to nearby wildlife and livestock, and
hazards for the crew working on the well site. It is impractical to
prevent all drips and leaks, especially on older wells which are
subjected to a variety of corrosive forces as well as vibration
from pump motors. So, many well are provided with containment
cellars, which are generally lined pits formed around the well head
with a sufficient diameter to catch the drips, runs and leaks. The
containment cellars are often provided with a permeable bottom,
such as gravel, 6' to 10' below ground level, which allows the
leaking oil and salt water to seep back down into the ground, well
below ground level, thereby preventing the environmental damage and
hazards. The top of these containment cellars are often provided
with a grate to prevent animals and crew members from falling into
the pit, but through which the leaking liquids can readily
pass.
SUMMARY OF THE INVENTION
A modular well containment cellar system having a bottom portion,
two co-planar half-panels joined to the bottom portion and
separated by a through-channel portion, and a one side wall joined
to a bottom portion and to the half-panels, forming a closed
container with an open top for mating to another cellar component
at the half-panels, wherein a well pipe may be received into the
through-channel. A plurality of drip diverters prevent
downward-moving liquid from running between the mated half-panels
and between the well pipe and the through-channel, thus avoiding
need for sealants or gaskets between the mated panels, the
through-channel and the well pipe, to capture dripped and running
liquids from above the containment cellar system.
BRIEF DESCRIPTION OF THE DRAWINGS
The description set forth herein is illustrated by the several
drawings.
FIG. 1 illustrates a component kit of a rectangular retrofittable
containment cellar according to at least one embodiment of the
present invention.
FIG. 2 provides mating-side view of a simplified illustration of
key portions of one container component of a rectangular
retrofittable containment cellar according to at least one
embodiment of the present invention.
FIG. 3 depicts mating-side view of a semi-cylindrical embodiment
container component of a retrofittable containment cellar according
to at least one embodiment of the present invention.
FIG. 4 shows mating-side view of a variation of the embodiment of
FIG. 3 with an optional "bump out" to accommodate pipe fittings,
joints, or system components within the through-channel of a
retrofittable containment cellar according to at least one
embodiment of the present invention.
FIG. 5 provides a non-mating-side view of the embodiment of FIG. 4,
including the bump out structure in the through-channel.
FIG. 6 illustrates a perspective view of a retrofittable
containment cellar according to the present invention, including
two ridge caps and two matted container components.
FIG. 7 provides an installed cut-away view of at least one
embodiment of the present invention as installed, with a drip
diverter component.
DETAILED DESCRIPTION OF EMBODIMENT(S) OF THE INVENTION
The inventor of the present invention have recognized problems in
the art not previously recognized or addressed in the art of
fabrication, construction and installation of containment cellars
for well heads and the associated well-top components (valves,
gauges, blow-out preventers, fittings, joints, etc.). In one known
manner of providing a containment cellar, the foresight of needing
or wanting a cellar in advance of installing the well-top
components must be had so that a pit can be dug around the well
head, and a single, continuous circular topless and bottomless
can-shaped steel pre-fabricated wall can be lowered over and around
the production pipe into the pit. Then, dirt is replaced around the
outside of the wall, gravel is dumped into and spread at the bottom
of the pit inside the wall, and optionally a grate is placed across
the top of the open pit.
This process, however, is not conducive to retrofitting an
operating well because the pre-fabricated can-shaped continuous
wall unit does not fit over the well-top components (tree, BOPs,
etc.). So, to use this method of creating a containment pit after
the well is in production, the well must be capped, the well-top
components removed, the wall and pit installed, well-top components
re-installed, and the well uncapped. However, once a well is in
operation and producing oil or gas, it is costly and risky to stop
its flow for any period of time, partly because of the loss of
revenue of the product not pumped during the shutdown, and party
due to the risk that the well will not return to its previous flow
rate. Further, even when this containment cellar approach is used
in advance of a well going into production, it still provides a
bottom which allows the leaked fluids to return to the ground,
potentially contaminating ground water, and resulting in lost
revenue for not capturing the leaked product.
Another method of creating a containment cellar, especially in a
producing well, is to leave the components above the wellhead in
place and the well in production, and then to carefully excavate a
pit around the well head. Then, forms are constructed for walls for
the cellar, and concrete is poured into the forms. After the
concrete has cured, the forms may be removed, gravel may be dumped
and spread into the bottom of the pit, and a grate may be placed
over the pit. This method can be more expensive than using the
pre-formed continuous wall system because the construction site is
often remote and/or secluded, and it shares the other drawbacks
regarding ground water contamination and lost revenue from the
leaked fluids.
Yet another method of creating a containment cellar includes using
pre-formed cellar components that must be fitted around a well
pipe, and sealed to the well pipe using sealants and/or gaskets.
The present inventor has realized that these sealants and gaskets
may fail, especially during shifting and settling of the dirt
around the cellar, and may also pose a difficulty when needing to
remove the cellar, well pipe, or both. And, in known
configurations, the exterior of the well pipe is exposed to the
corrosive fluids which are captured in the cellar, leading to
future maintenance requirements that can be costly and require a
risky shut down and restart of the well flow.
The present inventor has recognized these shortcomings in the art
of containment cellars, and has devised a method and a plurality of
components for a full containment cellar which is retrofittable to
a production well in a manner that allows the well to remain in
production during installation of the cellar components, and which
allows for capture of the leaked fluids. Further, according to at
least one embodiment, the exterior of the well pipe is encased and
protected by walls of the new modular cellar design to prevent the
well pipe from being corroded by the captured fluids. These and
other objectives and advantages of the present invention will
become evident to the reader in the following paragraphs.
Basic Containment Cellar Kit
Referring to FIG. 1, a kit (1) of components according to at least
one embodiment of the present invention is shown, including two or
more containment components (100), two or more diverter ridge caps
(601), and at least one diverter cone (703). The containment
components are provided with a means for attaching them to each
other, such as a set of flanges (120, 121) with holes for nuts and
bolts.
Containment Components
FIG. 2 shows a simplified structure for one embodiment of a
containment component (100) according to the present invention,
which as generally rectangular in shape, having a bottom (107), two
half panels (102, 103) with a through-channel (101) formed between
the half panels and the bottom (107), two side panels (104, 105),
and a panel (106) juxtaposed to the through-channel (101). These
sides and the bottom form a closed container with an open top (110)
for receiving dripped liquids.
FIG. 3 illustrates another embodiment according to the present
invention of a containment component (100') which is semi-circular
in shape, having a bottom (107), two half panels (102, 103) and a
through-channel (101), a one continuous curved side represented at
three points (104, 105 and 106) for orientation in the following
discussions, and an open top (110).
Mating of Containment Components
For installation without having to remove well head well-top
components, two or more of the containment components are placed
into an excavated pit with the half panels (102, 103) mated towards
each other, as shown in FIG. 6. The production pipe is captured in
the through-channels (101) of the two or more containment
components (100'), and the containment components are secured to
each other, such as by fixing bolts and nuts through flanges as
earlier shown in FIG. 1. In this manner, any fluid which is dripped
from the components or fittings above the top of the containment
system (600) may be received into the open tops (110).
Additionally, because the production pipe is actually encased
between the walls of the containment components, the production
pipe is not exposed to the captured fluids, thereby protecting
against corrosion of the production pipe.
However, some fluid may drip on top of the mated half-panels (102,
103), and could potentially run down between the half-panels such
that it is not captured within the containment components (100').
Optionally, to prevent this loss of fluids, ridge caps (601) may be
placed between the opposing and mated half-panels (102, 103), to
divert this portion of the leaked fluids into one of the two (or
more) containment components (100').
Installation of Containment System
FIG. 7 shows a cut-away view of at least one embodiment of the
present invention as installed, wherein the cut-away is taken
through the production pipe (705) and the containment components
(100' or 100). The well-top components (701) and pipe fittings
(702) may drip fluids (704), some of which may fall directly into
one of the containment component's open tops (110). Some of the
leaked fluid may run down the pipe or drip close to the pipe, which
is optionally diverted into the open tops (110) by a diverter cone
(703) as shown.
To install the containment cellar system without shutting down the
well or removing any of the well-top components (701), dirt (750)
is excavated away from around the well head production pipe (705) a
sufficient distance and depth to receive the two or more
containment components (100' or 100). The depth of the excavation
may be sufficient that the tops of the containment components (100
or 100') are essentially flush with ground level, or even above
ground level to prevent surface water from entering the cellar.
Prior to dropping the containment components (100 or 100') into the
excavated pit, preferably a levelling material such as sand or
gravel is placed in the bottom of the pit. After the containment
components have been maneuvered to capture the well pipe in the
through-channel, and the containment components have been secured
to each other, the excavated pit is back filled (751) around the
outside walls (104, 105, 106) of the containment components to
provide back pressure against the weight of accumulated fluids
(710).
Optionally, a grate may be placed over the open tops (110) of the
containment components for safety.
Reclamation of Accumulated Fluids
There are a number of methods to reclaim the fluids which are
accumulated into the containment system. First, a pumper truck may
be used by placing a drawing tube into the bottom of the
containment components, and the accumulated fluid (710) pumped out
of the cellar and into the truck. Another method would be to fit a
drain pipe or tube at the bottom of the containment components
which is then run to an accumulation tank, battery, or separator
unity. And, another method would be to remove the containment
components from the pit with the liquid in them, place them on the
back of a truck, and install empty containment components in their
place.
Through-Channel Bump-Out(s)
In the previously-discussed drawings, the through-channels (101)
were shown essentially cylindrical of consistent radius from bottom
to top of the container component (100, 100'). However, in some
applications, there may be flares in the channel needed to
accommodate components, joints, etc., in the pipe which is captured
in the through-channel, so a bump-out (101') may be formed in the
through-channel (101) as shown in FIG. 4 and FIG. 5. These
larger-radius portions within the through-channel may be provided
with a sloped top (120) to prevent possible pooling of liquids
which may be running down the inside of the through-channel above
the bump-out (101'). Other embodiments may include multiple
bump-outs, or bump-ins (smaller radius portions of the
through-channel), etc.
Submerged, Off-Short and Suspended Embodiments
The containment components can, in some embodiments, be fully
submerged for off-shore applications. And, with the addition of a
mounting flange above which the production pipe on which the two
(or more) containment components may rest, a containment system can
be built entirely above ground level (or water level), suspended
only by the production well pipe.
Materials and Manner of Fabrications
The containment components (100, 100') may be constructed of a wide
range of materials, as may be appropriate for various applications
and to meet any applicable regulatory requirements. Among these
materials are fiberglass, plastic, steel-reinforced concrete,
stainless steel, and aluminum. In one manner of fabrication, a
frame of square tube stock is constructed along the edges of the
containment component, and panels of metal, such as aluminum, are
disposed inside the frame, such as by welding. For such a
structure, holes may be drilled in the vertical elements of the
frame which define the outer edges of the mating half-panels (102,
103) so that they may be readily bolted to the corresponding
vertical elements on the mating containment component.
Pre-cast concrete units would be heavier, requiring more
substantial equipment to transport and install them, but also would
be more conducive to creation of larger containment cellars.
CONCLUSION
The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof,
unless specifically stated otherwise.
The corresponding structures, materials, acts, and equivalents of
all means or step plus function elements in the claims below are
intended to include any structure, material, or act for performing
the function in combination with other claimed elements as
specifically claimed. The description of the present invention has
been presented for purposes of illustration and description, but is
not intended to be exhaustive or limited to the invention in the
form disclosed. Many modifications and variations will be apparent
to those of ordinary skill in the art without departing from the
scope and spirit of the invention. The embodiment was chosen and
described in order to best explain the principles of the invention
and the practical application, and to enable others of ordinary
skill in the art to understand the invention for various
embodiments with various modifications as are suited to the
particular use contemplated.
It will be readily recognized by those skilled in the art that the
foregoing example embodiments do not define the extent or scope of
the present invention, but instead are provided as illustrations of
how to make and use at least one embodiment of the invention. The
following claims define the extent and scope of at least one
invention disclosed herein.
* * * * *
References